2007-C URRENT TOYOTA TUNDRA

July 18, 2011

PRODUCT CODES:

570, 571 & 572

INSTALLATION GUIDE

2007-CURRENT

TOYOTA TUNDRA

(800) 952-7655 • www.rollnlock.compage 2

STOP!If you have a bed with “Deck Rail System”, be sure to follow Step 1 on page 3.

If you Do Not have a bed with “Deck Rail System”, proceed to page 10 and begin with Step 1.

TOOLS NEEDED COMPONENTS INCLUDED

TailgateExtrusion

Tundra Clamp(s) x4 or x6

Pull-Strap

CargoShield

DrainTube(s) x 2

Housing

Track(s) x 2

3/8" Drill

1/2" Drill Bit

#2 Phillips Screwdriver

P2 Tip

HingedLid

Clamp(s) x4 or x6


Installation with Deck Rail SystemSTEP 1: BEDLINER MODIFICATION

Note: If the truck is equipped with a plastic drop-in bedliner, some alterations will be required. If no bedliner is present, proceed to Step 2.

A. To remove the bedliner for alteration, you must fi rst remove only the bulkhead deck rail (Photo 1).

B. The dotted lines in (Diagram 2) depict the area which must be cut out. Using a jig saw with a medium tooth blade, remove the bulkhead portion of the liner as indicated.Be sure to trim the bedliner's plastic tailgate panel as shown.

C. Place the liner back into the truck bed. The side panels of the liner will key under the deck rails (Photo 3). Note: Do not replace the bulkhead deck rail.

Photo 1

Photo 3

(2)1/2" DIAMETER HOLES located as required

TAILGATE PANEL

BEDLINER

CUT 1"

6 1/2” (Shortbed)

7 1/2” (Longbed)

5”

Diagram 2

Typical under-the-rail

bed liner


STEP 2: INSTALL THE HOUSING

A. If not already done, remove the bulkhead deck rail (Photo 4).

B. Place the Housing Assembly onto the bedrails (Photo 5). This is best accomplished with two people. Center it between the bedrails and leave about ½" of space between the bulkhead and the back of the Housing. Do not fasten the Housing in place.

C. Lift the Lid on the Housing and lean it against the cab (Photo 6). Place a rag between the Lid and cab to prevent scratches.

D. Making sure to leave the Pull-Strap connected to the threaded shipping Stud, rotate the Lock Lever to the 10 o’clock position (Photo 7).

Photo 5

Photo 6

Photo 7

Photo 4

STEP 3: INSTALL THE TRACKS ON DECK RAIL EQUIPPED BEDS

A. Remove the End Caps from the deck rails (Photo 8).

B. Insert threaded rectangular blocks (2 each side Crew Max bed; 3 each side short/long bed).

Photo 8


STEP 3: INSTALL THE TRACKS ON DECK RAIL EQUIPPED BEDS (CONTINUED)

Note: The threaded hole is off-centered and the block must be inserted with the hole closest to the bottom (Photo 9).

Note: Tracks for 2007 Tundra truck beds are shipped with the clamp setups for both applications with and without “Deck Rail Systems”. Before proceeding with an application with deck rails, you must first remove the Clamps shown (Photo 10).

C. Lower the tailgate and place the driver’s side Track onto the bedrail (Photo 11), and key it onto Housing Stem (Diagram 12), being sure that the Handle is properly engaged into the Track.

D. Using 1/4-20 x 1-1/4" countersunk screws, loosely secure the Tracks to the threaded blocks (Photo 13). Do not tighten.

E. Use #10-24 x 1/2" truss head screw and Cargo Nuts to secure the Tracks to the Housing Stems (Photo 14). Tighten these connections securely.

F. With the driver’s side Track in place, repeat sub-steps B-E for the passenger’s side Track.

Photo 14

Truss Head Screws

Cargo Nut

Photo 10

Photo 13

Photo 11

Photo 9

Diagram 12

Track

HousingStem


STEP 4: INSTALL THE TAILGATE EXTRUSION

A. Lower the tailgate and insert fi ve (5) plastic shims beneath the inside fl ange of the tailgate cap in the locations shown (Photo 15; Diagram 16).

B. Being careful not to strike the ends of the Tracks, close the tailgate and place the Tailgate Extrusion upon the edge of the tailgate, centering it between the Tracks (Photo 17).

C. While holding the Tailgate Extrusion in place, use a #8 x 3/4" self tapping screw and power screw gun to secure the center hole. (Photo 18)

D. Lower the tailgate and hold the Tailgate Extrusion tight and square to the tailgate. Secure each end hole (Photo 19) making sure the screw passes through the shim described in Step (A) above. Secure the two remaining holes.

Diagram 16

Photo 18Photo 17

Photo 19

Photo 15

NOTE: PLACE PLASTIC SHIM UNDER TAILGATE TRIM CAP AS SHOWN


STEP 5: ORIENTING THE TRACKS TO THE TAILGATE

A. Move to the front of the bed, lift up slightly on the Housing and shift each side back toward the tailgate (Photo 20) so that the Track End Caps contact the inside surface of the tailgate. Make sure the Track End Cap metal blocks contact the Tailgate Extrusion End Caps (Diagram 21). Note: If the Tracks are not positioned as shown, the Latch Mechanism will not function correctly.

B. With the Tracks in the correct position, you may now tighten the Track Clamps to the threaded blocks. Begin with the back clamps and be sure the Tracks remain level when tightening. Note: Do not use a power or pneumatic screw gun.

STEP 6: INSTALL CARGO SHIELD & DRAIN TUBES

A. Trim the track gasket 1" from the end of the Track (Photo 22).

B. Rotate the Lock Leverto the7 o’clock (closed) position (Photo 23), then remove the plastic wing nut and detach the Pull-Strap from the threaded Stud (Photo 24). Pull the Cover closed and latch it to the tailgate. Note: Do not allow the Cover to retract while the Housing Lid is open.

Diagram 21Photo 20

Photo 23Photo 22

Photo 24

Track

TailgateExtrusion


STEP 6: INSTALL CARGO SHIELD & DRAIN TUBES (CONTINUED)

C. Before lowering the Housing Lid, turn the Lid Pin Knobs ¼ turn clockwise, which will cause the pins to pop in if they are not already. Lower the Housing Lid, being sure that the Lid Pins snap into the receptors located on the Tracks.

D. To open the Cover pull back slightly on the Handle to relieve spring tension from the Latch Mechanisms and turn the Lock Lever clockwise to the 10 o’clock (unlatched) position.

E. Use 1/4-20 x 1/2" truss head screws and rubber washers to secure the Cargo Shield (Diagram 25). Note: The rubber washers go on the inside of the Cargo Shield.

F. Use 1/2" bit to drill holes for the drain tubes. Note that this process is easier if 1/4" pilot hole is drilled fi rst. The drain holes should be positioned in the center of the outermost bed plugs (Photo 26).

G. Always make sure the Pull-Strap is securely clipped to a fixed point in the bed.

STEP 7: TEST UNIT OPERATION

In Step 6 the Cover was opened (retracted). This should have caused the Lock Lever to enter the Lock Pocket and rotate to the 7 o’clock (latched) position.

A. To close the Cover, pull the Pull-Strap hand-over hand, allowing the excess strap to fall into the bed until you can reach the Handle. Place your hands evenly spread on the Handle and pull the Handle until it contacts the Tailgate Extrusion. As the Handle contacts the Tailgate Extrusion the spring loaded Latches (which were energized when the Cover was retracted) will automatically trip, simultaneously latching the Cover to the tailgate and side Tracks.

B. To open the Cover, pull back slightly on the Handle to relieve spring tension from the Latch Mechanisms and turn the Lock Lever clockwise to the 10 o’clock position. The Cover should retract on its own with only a slight push to set it into motion. When the Cover is retracting it is best to hold the Pull-Strap and allow it to slip through your fi ngers as the Cover travels. Applying pressure to the Pull-Strap as it slips through your fi ngers will act as a braking action, preventing the Handle from slamming into the Lid at high speed. The Cover must retract with only enough force to rotate and reset the Lock Lever and Latching Mechanism.

Cargo Shield

Truss Head Screws

Rubber Washers

Diagram 25

Photo 26


STEP 8: OPENING AND CLOSING / ADJUSTING THE HINGED LID

To Open:A. Grasp the Latch Pin Knobs, pull out and turn

knobs 90° to hold Pin in the unlock position.Grasp the Lid and lift. Rest the Lid against the back of the cab to hold open for service or cleaning (Diagram 27).

To Close:A. Lower the Lid and return the Latch Pins to

locked position by turning the knobs 1/4 turn.

If Lid is loose:

A. Raise Lid and loosen the nylock nut on each Lid Latch Bracket, move the top half of the Bracket one notch toward the tailgate. Tighten both nuts and close Lid (Diagram 28).

If Lid is tight:

A. Raise Lid and loosen the nylock nut on each Lid Latch Bracket, move the top half of the Bracket one notch toward the Housing. Tighten both nuts and close Lid (Diagram 28). Repeat if futher adjustments are needed.

LidKnob

BackofCab

Diagram 27

Nylock Nut Latch

TrackDiagram 28


Installation without Deck Rail SystemSTEP 1: BEDLINER MODIFICATION

Note: If the truck is equipped with a plastic drop-in bedliner, some alterations will be required. If no bedliner is present, proceed to Step 2.

A. Before removing the liner, measure from the inside face of the tailgate, draw 2" x 1-3/4" notch marks along the top edge of the liner on both driver and passenger side of the truck (Diagram 30). A white grease pencil is the best tool for this purpose.

B. The dotted lines in (Diagram 31) depict the area which must be cut out. Use a sharp utility knife to cut out the notches and a jig saw with medium tooth blade to cut out the area at the front. Be sure to trim the bedliner's plastic tailgate panel as shown.

C. Place the liner back into the truck bed.

STEP 2: INSTALL THE HOUSING

A. Place the Housing Assembly onto the bedrails (Photo 32). This is best accomplished with two people. Center it between the bedrails and leave about ½" of space between the bulkhead and the back of the Housing. Do not fasten the Housing in place.

Photo 32

Diagram 30 Code A B C 570 8 1/16" 46 3/4" 571 8 1/16" 33 3/4" 59 7/16" 572 8 1/16“ 46 3/4" 71 3/4"

(2)1/2" DIAMETER HOLES located as required

TAILGATE PANEL

BEDLINER

CUT 1"

6 1/2” (Shortbed)

7 1/2” (Longbed)

5”

Diagram 31

Typical under-the-rail

bed liner


STEP 3: INSTALL THE TRACKS

A. Use 6mm screws provided in the hardware package to secure the L- brackets to the threaded holes at the top of the bed walls (Photo 35). Tighten in place with the screw at the center of the oblong slot.

Note: Tracks for 2007 Tundra truck beds are shipped with clamp setups for both applications with and without “Deck Rail Systems”. Before proceeding with an application without deck rails, you must first remove the Clamps shown (Photo 36).

B. Lower the tailgate and place the driver’s side Track onto the bedrail (Photo 37), and key it onto Housing Stem (Diagram 38), being sure that the Handle is properly engaged into the Track.

STEP 2: INSTALL THE HOUSING (CONTINUED)B. Lift the Lid on the Housing and lean it against the cab (Photo 33). Place a rag between

the Lid and cab to prevent scratches.

C. Making sure to leave the Pull-Strap connect-ed to the threaded shipping Stud, rotate the Lock Lever to the 10 o’clock position (Photo 34).

Photo 34Photo 33

Photo 36Photo 35

Photo 37


STEP 3: INSTALL THE TRACKS (CONTINUED)C. Use #10-24 x 1/2" truss head screw and Cargo Nuts to secure the Track to the

Housing Stem (Photo 39). Tighten these connections securely.

D. With the driver’s side Track in place, repeat sub-steps B and C for the passen-ger’sside Track.

E. With the Tracks secured to the Housing, close the tailgate, being especially careful not to strike the ends of the Tracks. Now move to the front of the bed, lift up slightly on the Housing and shift each side back (Photo 40), until the Track End Caps contact the inside surface of the tailgate.

F. The Track Clamps should now be perfectly aligned with the L-brackets (Photo 41). If the Track Clamps do not align with the L-brackets, lift the Tracks just enough to access the L-bracket screws, and reset the L-brackets to align with the Track Clamps (Photo 42). Note: The Tracks can only go in one place (caps against tailgate), so the L-brackets must be moved to match the Track Clamps, not vice-versa.

G. Use 5/16-18 x 1" socket head bolts and lock washers to secure the Track Clamps to the L-brackets (Photo 43). Do not tighten yet.

Photo 40

Photo 43

Photo 42

Photo 41

Photo 39

Truss Head Screws

Cargo Nut

Diagram 38

Track

HousingStem


STEP 4: INSTALL THE TAILGATE EXTRUSION

A. Lower the tailgate and insert fi ve (5) plastic shims beneath the inside fl ange of the tailgate cap in the locations shown (Photo 44; Diagram 45).

B. Measure, locate and mark the center of the tailgate and Tailgate Extrusion (Photo 46).

C. Center the Tailgate Extrusion on the tailgate by aligning your marks. Being sure to hold the Tailgate Extrusion square to the tailgate, use a #8 x 3/4" self-tapping screw and power screw gun to secure the hole nearest the center, making sure the screw passes through the shim described in Step 4 (A) above (Photo 47).

D. Secure each end hole, again being sure to hold the Tailgate Extrusion tight and square to the tailgate (Photo 48), and then secure the two remaining holes.

Diagram 45

Photo 46

Photo 44

Photo 48Photo 47

NOTE: PLACE PLASTIC SHIM UNDER TAILGATE TRIM CAP AS SHOWN


STEP 5: ORIENTING THE TRACKS TO THE TAILGATE

A. With the Tracks already moved back so that the Track End Caps contact the inside surface of the tailgate. Make sure the Track End Cap metal blocks contact the Tailgate Extrusion End Caps (Diagram 49). Note: If the Tracks are not positioned as shown, the Latch Mechanism will not function correctly.

B. With the Tracks in the correct position, you may now tighten the Track Clamps to the L-brackets, beginning with the back clamps. However, if there is a space between the L-bracket and Track Clamp, a shim or shims will be required to prevent the Tracks from pitching downward when tightened (Photo 50). For proper function and water resistance, the Tracks must be set squarely to the bed.

Note: Do not use a power or pneumatic screw gun to tighten the Clamps.

STEP 6: INSTALL CARGO SHIELD & DRAIN TUBES

A. Trim the track gasket 1" from the end of the Track (Photo 51).

B. Rotate the Lock Lever to the 7 o’clock (closed) position (Photo 52), then remove the plastic wing nut and detach the Pull-Strap from the threaded Stud (Photo 53). Pull the Cover closed and latch it to the tailgate. Note: Do not allow the Cover to retract without the Lid in place.

Photo 50

Diagram 49

Photo 52

Photo 53

Photo 51

Track

TailgateExtrusion


STEP 6: INSTALL CARGO SHIELD & DRAIN TUBES (CONTINUED)

C. Before lowering the Housing Lid, turn the Lid Pin Knobs ¼ turn clockwise, which will cause the pins to pop in if they are not already. Lower the Housing Lid, being sure that the Lid Pins snap into the receptors located on the Tracks.

D. To open the Cover, pull back slightly on the Handle to relieve spring tension from the Latch Mechanisms and turn the Lock Lever clockwise to the 10 o’clock (unlatched) position.

E. Use 1/4-20 x 1/2" truss head screws and rubber washers to secure the Cargo Shield (Diagram 54). Note: The rubber washers go on the inside of the Cargo Shield.

F. Use a 1/2" bit to drill holes for the drain tubes. Note that this process is easier if a 1/4" pilot hole is drilled fi rst.The drain tubes should be positioned in the center of the outer most bed plug (Photo 55).

G. Always make sure the Pull-Strap is securely clipped to a fixed point in the bed.

Cargo Shield

Truss Head Screws

Rubber Washers

Diagram 54

Photo 55

STEP 7: TESTING OPERATION

In Step 6, the Cover was opened (retracted). This would have caused the Lock Lever to enter the lock pocket and rotate to the 7 o’clock (latched) position.

A. To close the Cover, pull the Pull-Strap hand-over-hand, allowing the excess strap to fall into the bed until you can reach the Handle. Place your hands evenly spread on the Handle and pull the Handle until it contacts the Tailgate Extrusion. As the Handle contacts the Tailgate Extrusion the spring loaded Latches (which were energized when the Cover was retracted) will automatically trip, simultaneously latching the Cover to the tailgate and side Tracks.

B. To open the Cover, pull back slightly on the Handle to relieve spring tension from the Latch Mechanisms and turn the Lock Lever clockwise to the 10 o’clock position. The Cover should retract on its own with only a slight push to set it into motion. When the Cover is retracting it is best to hold the Pull-Strap and allow it to slip through your fi ngers as the Cover travels. Applying pressure to the Pull-Strap as it slips through your fi ngers will act as a braking action, preventing the Handle from slamming into the Lid at high speed. The Cover must retract with only enough force to rotate and reset the Lock Lever and Latching Mechanism.


STEP 8: OPENING AND CLOSING / ADJUSTING THE HINGED LID

To Open:A. Grasp the Latch Pin Knobs, pull out and turn

knobs 90° to hold Pin in the unlock position.Grasp the Lid and lift. Rest the Lid against the back of the cab to hold open for service or cleaning (Diagram 56).

To Close:A. Lower the Lid and return the Latch Pins to

locked position by turning the knobs 1/4 turn.

If Lid is loose:

A. Raise Lid and loosen the nylock nut on each Lid Latch Bracket, move the top half of the Bracket one notch toward the tailgate. Tighten both nuts and close Lid (Diagram 57).

If Lid is tight:

A. Raise Lid and loosen the nylock nut on each Lid Latch Bracket, move the top half of the Bracket one notch toward the Housing. Tighten both nuts and close Lid (Diagram 57). Repeat if futher adjustments are needed.

LidKnob

BackofCab

Diagram 56

Nylock Nut Latch

TrackDiagram 57

Documents

2007-C URRENT TOYOTA TUNDRA